Package forming machine



F. E. BICKFORD PACKAGE FORMING MACHINE Sept. 2, 1952 5 Sheets-Sheet 2 Filed May l, 1946 o @ma E nmivh wm lo i w. ,G R w m E mm ,W E N K N m m e om! F e o o a o o o 0|* Un v m m sw. 5 E f T Q .nm ma A Mlm: o o o 0 o 0 o o a Nl m B E o w Y B Sept. 2, 1952 F. E. BlcKFoRD PACKAGE FORMING MACHINE 5 Sheets-Sheet 5 Filed May l, 1946 INVENTOR. FPEDEP/CK E'. BIC/(F020 4 TT'OIQNEYS sept- 2, 1952 F. E. BlcKFoRD 2,608,915

l PACKAGE FORMING MACHINE Filed May l, 1946 5 Sheets-Sheet 4 ||HII MI' :11,

JNVENTOR. Q F195 DEP/CK SUCK/rogo TTOQNEYS Sept. 2, 1952 F. E.' BlcKFoRD PACKAGE FORMING MACHINE '5 sheets-sheet 5 Filed May l, 1946 l INVoR. mfom/CK E. Ble/F020 @Y @wf Patented Sept. 2, 1952 4UINIVIED STATES PA1TEN'I`-v OFFICE PACKAGE FORMING MACHINE Frederick E. Bickfora, Westchester, N. Y; vfinalisation May 1, 1946, serial No. 666,270

(c1. ca -47) 11 Claims. 1

The present invention relates to a package forming machine and particularly to such a machine in which a package is formed from a sheet of thermoplastic material such as cellulose acetate or other thin moldahle flexible material of like character.,

In my copending application Serial No. 529,066, filed April 1, 1944 I described a packaging and package forming machine in which a scored and slotted blank was utilized'tol form a tray, two trays of slightly different dimensionsbeing usable to form a complete package. The present machine is in many respects'similar to that ofthe above mentioned' copending application, differing therefrom primarily that the blankutilized is not pre-formed but 'rather the acetate or `like moldable materialin sheet forni is fed from a reel and formed into trays in the. machine of this invention.

Furthermore, although the vmachine -of the copending application can" be utilized to form trays to ultimatelybe used as the halves of a complete package that machine was vprimarily designed to produce trays which were to be utilized as reinforcing ends for packages `and the machine was consequently' so designed as to permit severing the formed traysand adhering them to another and separate package/forming sheet.

As will be clear'rom the above description of the similarities and differences of the two machines this application is. a continuation in part of my copending application Serial No. 529,066.

In the present machine a'sheet of material the width of which is equal to the width of the Vbase plus twice the height oi a package to be formed is taken from a reel and passed throughfthe machine. During, its passage throughL vthe machine the sides are folded upwardly as are thev ends to form a traylikememben the corner folds being bent back along the sides of the tray and adhered, thereto toprovide reinforcing for the corners oi the tray structure. As is obvious two traysofslightly different dimensions may be utilized to form a complete package. the smaller tray servingr as the base andthe largeras the cover.

Itis an object of the'present invention to form packaging trays from a sheet of thin thermoplastic material such as cellulose acetate or like moldable material. y

It is a further object of the invention to provide a machine for4 producing such trays in which the folded corners are operated upon to crease them exactly and are then caused to be folded yback along the upstanding sides of the tray and adhered thereto'.

It is another object of the invention to provide a machine for producing packaging trays which may be either manually or automatically operated.

It is a further object of the invention to provide means for stripping the'formed trays from the plunger-member oi' the machine after their formation.

Other objects and features of the invention will become apparent when the following description is considered in `connection with the annexed drawings in Which- I Figure 1 is a side elevation of the machine of my invention;

Figure 2 is a longitudinal cross section, the section being taken on the plane of the line 2--2 of Figure 1;

Figure 3 is a fragmentary longitudinal crosssection taken on the plane of the line 3-3 of Figure l. This view shows a sheet of acetate or like thermoplastic material after it has been par tially formed;

Figure 4 is a fragmentary cross-sectional view of the machineof Figure 1, this View being taken on the plane of the line 3-3 of Figure 1. It shows the positions of the parts after the plunger of the machine has descended somewhat further than was the case in Figure 3;

Figure 5 is a transverse cross-sectional view of the machine of Figure 1, the cross-section being taken on the plane of the line 5-5 of Figure 1;

Figure 6 is a view similar to Figure but taken on the plane of the line 6 6 of Figure 1;

Figure 'i' is an enlarged fragmentary crosssectional View showing particularly one of the early stages in the formation ofjthe tray and the positions of the operating parts of the machine at'this stage. This View is taken on the plane of the line l-l of Figure 3 and shows the parts of the machine in the same positions as are indicated in that ligure;

Figure 8 is an enlarged fragmentary crosssectional View taken on the plane of theline 8 -8 of Figure 4 and showing the positions of the various parts of the stage of operation depicted in Figure 4;

Figure 9 is a fragmentary horizontal view of the machine, the view being taken on the plane of the line 9 9 of Figure 8 and showing particularly the mode of forming thecorners of thev packaging tray; i

but showing the position of the various parts of the machine at a later stage in the operation and specifically during the period when the folded corners of the packaging tray are being creased and formed into 'their final shape;

Figure l1 is a fragmentary horizontal crosssectional view taken on the plane of the line |I|| of Figure 10 showing the cooperation of certain rollers to crease the triangular corners of the tray;

Figure .1 2 isa, view similar to Figures 7 through 10 but showing the parts of the machine when the plunger has descended still further and the formed corners have been bent back along the sides of the tray and adhered thereto to form' the complete packaging tray; and Y Figure 13 is a fragmentary cross-sectional view taken on the plane of the linev |3=|3 of Figure 12 showing more particularly the mode of bending the corners into their position against the sides of the tray.

Referring now to the drawings, the machine of the present invention comprises a channel-like member having a slot in the base thereof, this slot terminating at the points designated I2, Figure 2. Beneaththe channel member I9 are a number of plates I3, -I5 and I9 (Figures 5 and 6) which are arranged to provide a rectangular slot of substantially the same size asY that in the channel I9 immediately "beneath that in channel I0. Channel I0 is provided with a recessed undersurface above the slot formed by plates I3, I5 and |9 to provide for a bar I4 which slides into the recess from the right as seen in Figure 1 and forms-a mold bottom during one of the stages of operation of the machine.

Beneath plate" |3 is plate I5 which is recessed as indicated at I6 and provided with a rectangular slot I1. The recess I6 provides a guiding means for the bar I8 which moves in from the left as seen in Figure 1 and forms a bottoni for the mold during another stage of the operation` Afxed to the plate I5 is a further generally channel-shaped plate I9 which completes the mold structure and is provided with a rectangular slot 29 through Which the completed tray passes prior to its discharge.

Above and spaced from the channel member I0 there is mounted a plate 2| which is recessed on its undersurface as indicated at 22 of Figures 5 and 6 to provide a guide for a vacuum feed member 23 which member reciprocates being driven either manually or automatically. The vacuum feeding member 23as is seen in Figure 2, comprises av generally rectangular plate provided With a plurality of `passageways 24 and ports 25 through which a vacuum is drawn by means of the two-way valve 26 and the vacuum pump 21. -As indicated in Figure 1, the member 23 may be horizontally reciprocated and may be moved from the position indicated in Figure 2, to a position in Which its right hand edge lies beyond the right hand edgeof the slot in the channel member I0, an amount equal to the height of the tray.

The upper horizontal surfaces of the upstanding armsA of channel member I0 are recessed at each side of the slot I I as indicated at 28 (Figure 5) to form a space for entry of a sheet to be operated upon. Formed in the upper surfaces of the arms of channel I9 are ports 29 and passages 30 communicating therewith which are connected by means of the bores 3| in channel member I6 and the pipes 32, Figures 2 and 5, to the two-way valve 26 and through it to the vacuum pump 2l.

Spaced above the plate 2| is a plate v33 which, together with the plate 2|, is fastened to the 4 channel member l0 by means of the screws 34. Plates 2| and 33 are provided with rectangular slots which serve as guides for the plunger member 35 which is raised and lowered during the operation of the machine either by hand or automatically in any suitable manner.

Plunger means 35 is dimensioned in accordance with the thickness of the material of which the package tray is to be formed, that is, so dimensioned that when insertedina molding chamber there will bea space between each plunger edge and its cooperating chamber side Wall, which space Will be equal to the thickness of the sheet material from which a package tray is formed. -At the ends of the channel member I0, the channel is vfilled in as, for example, by the blocks 36 (see Figure 7) which may be fastened within the channel'in any suitable manner as by means of screwsor by welding or may be made integral with the channel member I0. At the outer ends of the rectangular slot II the upstanding walls IIla of the channel I0 are provided with a narrow slot 3l' (Figures 1 and 2), the outer sides of the lslots being on a line With the blocks 36 so that there is formed' an end forming surface for operation upon the ends of the blanks as will be described. The inner sides of the slots 3l form end surfaces on the side walls of the channel member Ill'to cooperate with the surfaces of end forming.. platesv39 for forming the ends of the blank as hereinafter described. The blocks 36 are cut away, asis indicated at 38 (see Figures 7, 8 and 10) to conform to the configuration of an end vforming plate 39 which is pivotally mounted ona shaft 49 extending ybetween the upstanding arms'of'the channel I0. This plate 39 is pinned to thesh'aft 40 by'means. of the pin 4I and is spring'urged to the position' in which it is shown in Figure 7. A stopv 42 is provided to limit the rotary movement of the plate 39 under urge of the spring 43.' When the end forming plates 39 become parallel to the plunger ends they provide the ends 'of the mold. Fixed to the edge of the upstanding arms of, thechannel D adjacent each of the slots 3l is agresilient finger 44. Each of these ngersare 'designed to cooperate with a rollerjshortly to jbe described in order to press a 'triangular fold into the corners of the blank as the blank isoperated upon by the plunger 35.

The slots 31 are widened at the inner sides thereof at the base' of the channel member I9 to provide space forfour rollers 45, which rollers cooperate with rollers 46 which are mounted in bores in the upstanding arm of the channel IG adjacent the outer edge of the slot at-each corner of the rectangular slot in the channel I0. Additionally, a roller -Il is provided at each corner of the rectangular slot II lying above the roller i6-and cooperatingnwith vthe respective resilient finger 44. Rollers45, 46 and 41 are mounted on shafts'48,^-49'and 501,' respectively, these shafts extending through bores in the upstanding arms ofjthe channel I0 to the exterior thereof. Mounted o n :the shafts4 48,' 49 and 50, respectively, are gears 5|52 and 53. Gear 5| meshes with gear 52 and gear 5|jis driven by a gear 54 mounted on a stubv shaft 5,5'which is in turn rotatably mounted inthe upstanding arm of the channel I U. Gear 53meshes with a gear 56 mounted on a stub shaft 51 and gear 56 in turn meshes with gear 5urnountedl on a stub shaft 5S. Gears 54 and 584 mesh with a rack 60 which is fixed to the plunger35 andj'moves therewith. The bottom platev |'9 is recessed at the four places indicated in the shearing edge (Figure 7).

v at 6| in Figure 1 to permit the racks 66 to descend to their lowermost limit of movement.

As has been indicated, the blanks are folded at their ends in such a manner as to produce a triangular-shaped extension of the ends. which projects outwardly'at each corner of the, folded blank. Incompleting the formation of the tray structure, these triangular corners are folded back along the sides of the tray and adhered thereto. In order to accomplish this purpose there are provided four folding members 62 (see Figure 13) which members are mounted in the enlarged lower portions 38 of the slots 3'|. Each end folding member 62 is mounted on a shaft 63 which extends downwardly through the plates l5 and I9. and has mounted on its outer end a gear 64. Each gear 64 meshes with a gear 65 which is mounted on a shaft 66 which extends upwardly through the plates I9 and l5, the arms of the channel member ||l and the plates 2| and 33. On each shaft 63 between the plates 2| and 33 '1s a gear 6l, these'gears being fixed for rotation with their respective shafts 66. Each gear v|51 meshes with a gear 68 mounted on a short shaft 39 extending between plates 2|` and 33. Two of the gears 6B mesh directly with a gear sector 'lil made integral with the collar fixed to a shaft 'i2 whichV is supported in the plates 2| and 33. The remaining two gears 68 mesh with gears |3 which are mounted on stub shafts in the same manner as are gears 68 and in turn mesh each with one of the two gear sectors lil. Due to the interposition of the additional idler 13 at the diagonal corners of the machine, the end folding members 62 are caused to move inthe correct direction to fold the triangular extensions of the end of the folded blank against the sides of the blank. The shafts ,12 may be oscillated to cause this result in any suitable manner as, for example, by means of the helically slotted collars and pins which are illustrated in my above mentioned copending application. Whatever means is used to oscillate these shafts is, of course, operated in proper timed relationship to the remaining operations so that the extensions of the ends of the blank ar-e folded against the sides at the proper moment. e

A knife blade 15 is vmounted adjacent to the plunger'35 and is guided by slots inthe plates 2| and 33, as seen particularly in Figures 7 and and 8. The blade 15 is mounted in any suitable manner as, for example, by means of the block 13 and cap block which are vertically reciprocable in any suitable manner asv by means of a manually operated lever or bellcrank. Cooperating with the bladef'l is a shearing edge 18 which is 'mounted in a recess in the top of the left hand one of the blocks 36 and whichis. adjustable due to the use of a screwv 7 3 in a groove As is clearly indicated in Figures 7 through 10, the knife blade and shearing edge 18 are so located as V:to sever the proper amount of material to form a blank from which trays are molded. f,

In the preferred form of my invention the plunger 35 is provided with passageways 39 and ports 8|, these ports being arranged on the bottom surface of the plunger and` in such position that application of pressure fluid to the passageways 5b will cause the formed tray to be expelled from the plunger. The trays removed from the plunger may be received upon a belt such as is indicated in dotted lines in Figure 1 and designated 82, this belt being formed of chain links which are rectangular in shape and ofa size slightly greater than that of 'the .trays l being formed. Each of these chain links has a perforatedl bottom, the perforations being shown at 'IS (Fig. 1), andA since the chain is adapted to be movedintermittently, the perforationsin the bottom. of the links may be in alignment with exhaust ports 83 -in the upper surface of a plate 84 during the time when the chain 8.2 is stationary. Thus by a combination of pressure on the inner surfaces of the bottoms of the formed trays and. suction on the outer surfaces of the bottom, the formed trays are caused to be removed rapidly from the plunger 35and to be seated within they rectangular chain links.

The foregoing fhas described the major features of construction of the machine. TheV remaining features will be described during the'following description of the operation of the machine.

A roll of cellulose acetate 3 or like thermoplastic material of proper width and having the requisite qualities of flexibility and moldability is mounted on a suitable reel, not shown, and the material designated 85 (Figure 1) is positioned beneath the vacuum registration plate 23. The valve 26 isthen operated to cause a suction to be applied to the material 85 through the ports 25 in member 23,y While the suction continues rto be applied member 23 is moved manually or in any suitable automatic manner to the right as seen -in Figures 1 and 2, until it reaches the right handend of the recess 22 in the plate 2|. At this time the member lies ina position such that the central rectangular portion of the sheetof material is directly above the slot in the base of the channel member I0 and in position such that. the sides of the sheet are above the recesses 2B in the upstanding arms of the channel member |0.

Upon arrival of the member 23 at this position, the valve 26 is operated vto release the suction from the plate 23 and to apply suction to the pipes 32, passages 3| and 3i! and ports 29 to the lower surfaces of the sides of the sheet 85. Next the plate 23 is vmoved. to the left and into position to pick up a new length of material and move it into position to be operated upon. Then the knife blade 'l5 is moved downwardly and, cooperating with'the shearing edge 18, severs the positioned sheet of material from the roll. Next plunger 35 descends and comes into contact with the central rectangular portion of the severed sheet causing the sides of the sheet to fold upwardly. At the same time the ends of the blank are caused to be folded upwardly by cooperation between the ends of the plunger 35 and the face of the forming plate 39. Thus when the plunger has descended to the position illustrated in Figures 3 and 7, the sides of the blank as well as the ends extend upwardly at substantially a 45 angle and a triangular fold, indicated at 86 in Figure 3, is formed at each corner of the blank.

Further descent of the plunger 35 brings about rotation of the end forming plate 33 and causes the sides and ends of the blank to extend upwardly at right angles to the base thereof, the

triangular folds 86 extending into the slots 31, as is best seen in Figures 9 to 11. Shortly thereafter these triangular folds 33 are pressed between the end forming plates 33 and theresilientiingers 44 thereby causing the fold line to be pressed' into :the material. Continued descent of the plunger brings the folded triangular corners 8B between the ends of `the resilient fingers 44 and the rollers 41 and thus increases the creasing action. At this time, of

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course, the Vrollers 41 are'rotating due to the movementof the racks 60 and the action thereof on the gear trains previously described. Next the plunger descends still further and carries the triangular folds 86 between the pairs of rollers 45 and 46 completing-the creasing of the fold line of these triangular corners, the 'rollers 45 and 46 being rotated under drive of the-racks 6U. At about this time, the descent of the plunger 35 brings the base of the partially formed tray against the heated bottom bar or mold member I4 which at this time is in its left hand position having been driven there by means of the action of 'the' gear 81 on the rack teethas formed on the lower surface of the bar I4. Gear 81 may be driven in any suitable manner as, for example, by means of avcrank or automatically, but in any event is moved in timed relationship to the operation of the other machine parts.

As has been stated, the bar I4 is heated so that the formed base edges of the tray are set in or molded in their desired right angle position. Shortly after this the gear 81 is operated to move the bar I4 to the right exposing the rectangular slot in the plate I3. Shortly after this the plunger 35 again descends, the rollers 45 and 46 resume-their rotation, the final creasing of the fold lines is effected, and theforners 8E pass from between the rollers 45 andA 46. Following this, the descent of the plunger is again halted by the bar I8 which is similar to the bar I4 and is similarly driven by means of rack teeth 89 on the bar and cooperating gear 9D.

At this stage the partially formed tray is in position to be Voperated upon by the corner folding members 62 which, as is clearly indicated in Figure 13, rotateA from their normal position, shown in dotted Vlines in-Figure 13,v to their operated or full line position and thereby cause the triangular corners to be folded back against the sides of the tray members and adhere thereto.

In order to insure such adhesion, the folding members 62 may be heated in any suitable manner, such for example as by the use of electrical resistance heaters, as shown in Figure l, the mold and the folding members 62 then being heated by conduction from the heated bottombar or mold bottom I8. As indicated, an electrical resistance heater I8a is utilized to supply heat to the bottom bar I 8, this heater being connected in the usual manner to any suitable power source.

After adhesion of the corners, the bar I8 is moved to the leftY and the plunger caused to descend through the plate I5 and the base plate I 9 and into the position indicated in the dot-dash lines in Figure l. When the plunger is seated within one of the rectangular links of the chain 82, its descent is terminated and pressure is applied to thevports 8| While at `the same time suction is applied through the exhaust ports 83 and perforations 19 in the :bottom of the link to release the formed tray from the plunger 35. Immediately thereafter the plunger 35 is caused to rise to its uppermost position, the -valve 26 is again operated to cause application of suction toV the plate 23, and a new sheet of material is fed to the machine and the operations described above repeated to form anotherin' the succession of trays. x

While I have described a preferred form of my invention it will be understood that various modifications thereof are possible and I do not desire, therefore, to be restricted to the particular'details shown anddescribed, but only to the scope of the appended claims.

What is claimed is: l'

1. In a device for making package trays from thermoplastic sheet material, in combination, a mold member having a removable bottom, upstanding sides extending above said bottom, upstanding end members extending across said side members and slightly spaced therefrom, a reciprccable vacuum registering member mounted to move above the molding chamber formed by said bottom member and side and end members, means for applying a vacuum to said reciprccable member, means for mounting a roll of flexible moldable material in position to be registered on said reciprccable member, means in said mold side Walls for drawing a vacuum therethrough, and means for releasing moldable material carried by said reciprccable member from said member While in position above said mold and for simultaneously applying a vacuum to said mold side walls to register the flexible mold material thereon.

2. In a device for making package trays from thermoplastic sheet material, in combination, a mold member having a removable bottom, upstanding sides extending above said bottom, upstanding end members extending across said side members and slightly spaced therefrom, a reciprocablevacuum registering member mounted to move above the molding chamber formed by said bottom and side and end members, means for applying a vacuum to said reciprccable member, means for mounting a roll of flexible moldable material in position to be registered on said reciprccable member, means in said mold side walls for drawing a vacuum therethrough, means for releasing moldable material carried by said reciprccable member from said member while in position above said mold and for simultaneously applying a vacuum to said mold side walls to register the flexible moldable material thereon, and means for severing a portion of said moldable material equal in length to the length plus twice the height of the tray to be formed from the sheet.

3. In a device for making package trays from thermoplastic sheet material, in combination, a mold member having a removable bottom, upstanding sides extending above said bottom, upstanding end members extending across said side members and slightly spaced therefrom, means for'feeding a sheet of moldable material above the molding chamber formed by said bottom and side and end members, means for severing a length from said sheet equal to the length plus twice the height of the tray to be formed, means for forcing the severed sheet into said chamber to fold the sides and ends of the severed portion upwardly to form a tray like member having the extremities of its ends extending into the spaces between the mold sides and mold ends, and means adjacent to said space for creasing the folds formed'at the extremities of said ends of said tray like member.

4. In a device for making package trays from thermoplastic sheet material, in combination, a mold member having a removable bottom, upstanding sides extending above said bottom, upstanding end members extending across said side members and slightly spaced therefrom, means for feeding a sheet of moldable material above the molding chamber formed by said bottom and side and end members, means for severing a length from said sheet equal to the length plus twice the height of the trays to be formed, means for forcing said severed length into said chamber to fold the sides and ends of the severed portion www standing sides extending 'above said bottom, upstanding ends extending across Asaid sides and being slightly spaced therefrom, plates mounted in said upstanding ends, said plates being generally T-shaped, means for feeding a sheet of material above the molding chamber formed by said bottom and side and end elements, plunger means of a cross-sectional area, substantially equal to that of the mold chamber, for forcing said moldable material into said mold chamber to thereby cause the sides. and ends of said sheet to be folded upwardly and to form a triangular fold at each extremity of each end of the tray formed thereby, said triangular folds extending into the space between said mold side members and end members, means adjacent each triangular crease for pressing the crease, additional means adjacent each crease for further pressing the said crease, said additional meanscomprising a pair of rollers situated on each side of each said end of each extremity, said rollers of both said first andsaid additional creasing means being driven by said plunger means, means operable upon said plunger meansvseating against said removable bottom member of said mold for folding the said triangularly creased extremities of the ends of said sheet against the sides ofthe formed tray like member, means for removingsaid bottom member from said mold, an additional mold chamber mounted beneath said main mold chamber, said additional mold chamber having a removable bottom member, said plunger means being operable to position said formed tray against said additional removable mold bottom, heating means for causing adherence of said folded triangularly creased extremities to the sides of the formed tray and for setting ali folds, means for removing said second removable bottom member, said plunger means moving downwardly to remove the formed trays from the entire mold structure, and means to remove the formed tray from the plunger means, said last mentioned means comprising a vacuum element on which the plunger deposits the'formed tray.

l1. In a device for making thermoplastic package trays from sheetmaterial, in cibina= tion, a molding chamber having a removable bottom, upstanding sides extending above said bottom, upstanding end members extending across said side members and spaced therefrom a distance equal to the thickness of the sheet material utilized, means for feeding a sheet of material above the molding chamber formed by said bottom and side and end members, means for severing a length from said sheet `equal to the length plus twice the height of thetray to be formed, means for forcing the severed sheet into said molding chamber to fold the sides and ends of the severed portion upwardly to form a tray-like member having the extremities of its ends extending into the lspaces between the mold sides and the mold ends. means for creasing the triangular folds formed at the extremities of said ends of said tray-like member, and means for heating at least one element of said molding chamber to set the creases formed in said sheet material.

FREDERICK E. BICKFORD.

REFERENCES CITED The following references are of record in the le of this patent:

UNITED STATES PATENTS Number Name Date 988,359 Kuster 1 Apr. 4, 1911 1,186,102 Johnson June 6, 1916 1,423,097 Ferguson July 18, 1922 1,908,823 Danieli May 16. 1933 2,132,859 Mednick et a1 Oct. 1l, 1938 FOREIGN PATENTS Number Country Date 381,190 France Oct. 31, 1967 

